Tubular member flaw detection

ABSTRACT

A method for ultrasonically inspecting a tubular member which has a first surface spaced-apart from a second surface by a thickness of the tubular member, and two spaced-apart ends the method including transmitting sonic beams to the tubular member with transducer apparatus which are reflected from the first surface and from the second surface, the transducer apparatus controlled by control apparatus, while to inspect the first surface for first surface defects, moving the transducer apparatus adjacent sensing apparatus which signals the control apparatus to cease processing of signals related to inspection of the second surface, and, the transducer apparatus continuing to transmit sonic beams for the inspection of the first surface, and completing inspection of substantially all of the second surface for second surface defects while continuing to inspect the first surface.

RELATED APPLICATION

This is a continuation-in-part of U.S. Ser. No. 09/930,117 filed Aug.14, 2001, incorporated fully herein for all purposes now U.S. Pat. No.6,578,422.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention is directed to: ultrasonic systems and methods fordetecting flaws in tubular members; in certain particular aspects, tosuch systems and methods that are automatic and which accurately detectflaws near or at the ends of a tubular member such as pipe, tubing,casing, or other oil field tubulars; and, in certain aspects, to systemsand methods for detecting defects in welds in, on, or between tubularmembers.

2. Description of Related Art

Flaws and defects in tubular members can result in the failure of thetubulars. Replacement or repair of a defective tubular can betime-consuming and expensive. In the oil and gas industries, tubularmembers used in drilling and other oil field operations are examinedbefore use to detect and locate defects. Often a defect can be removedand the tubular used for its intended purpose. In other cases, thedefect cannot be fixed and the tubular is rejected. Whether the tubularmember can be used is based on characteristics of a defect, e.g. size,shape, location and orientation.

In some cases, defects located on a surface (interior or exterior) of atubular can be visually characterized and examined to determine whetherremoval of the defect is necessary and possible—and whether removal isfeasible by grinding or other means; but often such visual examinationof a defect is not accurate or is not possible.

Certain prior art ultrasonic inspection devices have used sonic beams tolocate defects in tubular members. In certain systems the apparatusemployed uses a piezoelectric crystal or crystals, each of whichproduces ultrasonic vibrations in response to the application of avoltage. Such systems often use a method in which a crystal is held in aposition relative to the pipe surface to transmit a short duration sonicwave pulse of beamed energy into the wall of the pipe at an angle suchthat a flaw or discontinuity in the pipe causes the waves to bereflected back and produce a voltage response in the crystal, which isthen de-energized immediately following the pulsed emission of a sonicwave so that reflected waves can be received during the de-energizedperiods to produce a corresponding electrical signal which may beanalyzed for determining the nature and location of flaws. For example,U.S. Pat. No. 4,217,782 describes an ultrasonic inspection device forinspecting tubular members for the oil and gas drilling industries thatemploys two pairs of line-focused transducers that transmit sonic beamshaving a rectangular beam cross-section of about ¾ inch in length. Afirst pair of the transducers transmits sonic beams longitudinally intothe member to detect transverse defects. The second pair transmits sonicbeams transversely into the member to detect longitudinal defects. Thetransducers in each pair transmit sonic beams in opposite directions.Two additional transducers monitor the wall thickness of the tubularmember. Sonic beams transmitted longitudinally and transversely are usedfor the inspection of tubular members since defects are visible to onlyone or the other. Some flaws and defects are invisible to bothlongitudinally and transversely transmitted sonic beams. In certainprior art systems, the ultrasonic inspection device of U.S. Pat. No.4,217,782 has been modified to include four spot-focused transducersthat transmit sonic beams having a circular beam cross-section obliquelythrough a tubular member and a pair of transducers that transmit inopposite directions has been used to detect defects in tubular membersas described in U.S. Pat. No. 3,289,468 since a given defect may beinvisible to a transducer looking at it from one direction and visibleto a transducer looking at it from the opposite direction.

In order to characterize a defect for size, shape, and orientation sonicbeams are, in certain prior art systems, transmitted from severaldifferent directions followed by the receiving of beams reflected fromthe defect. As described in U.S. Pat. No. 3,332,278, reflected beamsfrom one transducer have been received by several transducers to detectsome of the defects.

U.S. Pat. No. 4,718,277 discloses an ultrasonic inspection device havingan array of opposing transducers that longitudinally, transversely, andobliquely transmit sonic beams through tubular members having a range ofdiameters such that refracted beams meet on the inner surface of themembers. Alternate halves of the array of transducers transmit andreceive sonic beams reflected from defects in the tubular members usingboth the pulse-echo and pitch-catch methods.

U.S. Pat. No. 5,007,291 discloses ultrasonic inspection apparatus withcentering means for tubular members that has pipe inspection apparatuswith transducers for transmitting pulsed beams of ultrasonic energylongitudinally, transversely and obliquely into the wall of the pipe fordetection of flaws. The apparatus includes a motor driven chuck forrotating the transducers about the a pipe and a motor driven roller foraxial movement of the pipe whereby the transducers move in a helicalscanning path. A control system maintains the axes of the pipe andcircle array of transducers in coincidence and with hydraulic controlsmaintains each transducer at fixed distance to the pipe for soniclycoupling thereto by a flowing liquid whereby a shear wave is generatedby each beam in the tubular wall. The transducers comprise multiplepairs, the members of which are diametrically opposed and transmit inopposite directions, for transmitting longitudinally at angles of 12degrees, 27 degrees and 42 degrees to the pipe axis both clockwise andcounterclockwise with one transducer of each pair disposed to transmitforward and the other reverse. For longitudinal flaws, one transducer ofa pair transmits transverse clockwise and the other transversecounterclockwise. All transducers which transmit in a given directionare arrayed in the axial direction of the pipe. Pulsers simultaneouslyand repetitively energize and de-energize all forward transmittingtransducers and after each such transmission pulsers simultaneously andrepetitively energize and de-energize all reverse transducers.Reflection signals of predetermined strength are recorded and activatean alarm. A compressional wave transducer for determining wall thicknessis included.

U.S. Pat. No. 5,313,837 discloses an ultrasonic thickness gage for pipe,which in certain aspects is a compact ultrasonic tester involvingrotating sensors. A processor rotates with the sensors so that theoutput signal of the processor goes through slip rings, rather than tooutput signal of the sensors. A spraying system is incorporated inconjunction with rollers. The rollers take the applied spray on the pipesurface and paint a film on the outer pipe surface to allow a goodcontact for meaningful results. A floating shoe is provided for holdingeach sensor against the pipe wall. The sensors are biased into contactwith the pipe surface and the machine can handle different diameters ofpipe. By controlling the pipe speed of advance and the rotational speedof the sensors, a large percent coverage of the pipe wall is assured.The machine is compact and can be installed behind existingelectromagnetic/gamma testers without major modifications topipe-testing facilities.

U.S. Pat. No. 5,585,565 discloses a method for the ultrasonic inspectionof pipe and tubing and a transducer which has an elastic membrane usedto form a reservoir of ultrasonic fluid coupled to ultrasonictransducers with the membrane conforming to the surface of the tubingbeing inspected. Guide wheels maintain the membrane out-of-contact withthe tubing during relative rotational movement of the assembly andtubing during inspection. Water is introduced between the membrane andthe tubing to provide ultrasonic coupling of the tubing to thetransducers through the fluid of the reservoir. Each of the patentsmentioned above is incorporated fully herein in its entirety for alpurposes.

Known automated ultrasonic systems for detecting flaws and defects intubulars have been unable to adequately, accurately, and correctlydetect inner surface defects relatively near the ends of the tubularmember, e.g., within two feet or within eighteen inches of the ends upto the end boundary surface. For example, about eighteen to twenty fourinches of the length of a thirty foot casing, ten and three-fourthsinches in diameter, is often not accurately examined by certainautomated prior art systems. The ends of such tubulars are oftenexamined manually with portable electromagnetic or ultrasonic testingequipment in a time-consuming process. In various prior art systems thesignals from the ends of the tubulars are not accurately distinguishedfrom signals reflected from defects near the ends of the tubulars. Thisinability to distinguish and differentiate these signals renders thesesystems and methods inadequate for inner surface defect detection nearthe tubulars' ends.

There has been a need for an ultrasonic inspection device that iscapable of correctly and efficiently detecting and characterizing flawsand defects in tubular members and for such systems and methods that cando this for inner surface defects near or at the ends of the tubulars.There has long been a need for systems and methods for detecting defectsin welds in, on, or between tubulars, e.g., but not limited to, theexamination of girth welds of tool joints.

SUMMARY OF THE INVENTION

The present invention, in certain aspects, discloses a method forultrasonically inspecting a tubular member, the tubular member having afirst surface, a second surface, the first surface spaced apart from thesecond surface by a thickness of the tubular member, and twospaced-apart ends including a first end of the tubular member, themethod including transmitting sonic beams to the tubular member withtransducer apparatus such that sonic beams are reflected from the firstsurface of the tubular member and from the second surface of the tubularmember, the transducer apparatus controlled by control apparatus, whilecontinuing to inspect the first surface of the tubular member for firstsurface defects, moving the transducer apparatus adjacent sensingapparatus which signals the control apparatus to cease processing oftransducer apparatus signals related to inspection of the secondsurface, and, the transducer apparatus continuing to transmit sonicbeams for the inspection of the first surface of the tubular member, andcompleting inspection of the second surface of the tubular member forsecond surface defects while continuing to inspect the first surface ofthe tubular member for first surface defects.

The present invention discloses, in certain aspects, an ultrasonicinspection device useful for inspecting a tubular member includingtransducer apparatus for transmitting sonic beams and for receivingreflected beams thereof from inner and outer surfaces of the tubularmember, and from defects of the tubular member, the reflected beamsincluding beams reflected from an outer surface of the tubular memberand from an inner surface of the tubular member, and from a defect ofthe tubular member, and apparatus for differentiating the reflectedbeams, apparatus for producing signals corresponding to informationabout the reflected beams, including a defect signal having informationabout the defect, and an end signal from proximity switch apparatuspositioned with respect to an end of the tubular member, and apparatusfor continuing inspection of one surface of the tubular member followingcessation of inspection of the other surface of the tubular member.

The present invention, in certain embodiments, discloses a system fordetecting defects in tubular members which is capable of examiningalmost all of the entire length of the tubular; and, in certain aspects,which can accurately detect flaws including inner surface defects insubstantially all of a tubular's length and near or at its ends. Incertain aspects this is accomplished with a system that nullifies,cancels, or ignores information from a signal reflected from a tubularend (or signals)—i.e. other than a signal or signals related to innersurface defects—transmitted to and reflected from the tubular. In manyinstances a signal reflected from a tubular end is misinterpreted as, isnot easily distinguishable from or is indistinguishable from a signalreflected from an inner surface defect near a tubular end and such asignal often cannot be accurately analyzed to determine whether there isa defect near the tubular end. A misinterpretation of such a signal canalso result in a false indication of an inner surface defect.

In certain embodiments according to the present invention, signalinformation related to a signal reflected from the end of the tubular isused by an analyzing apparatus to determine the distance from ultrasonictransducers to the end of the tubular toward which the transducers aremoving, but not for outer surface (outer diameter or “O.D.”) flawdetection; and, at the same time, the system does send and receivesignals for the examination of the inner surface (inner diameter or“I.D.”) of the tubular member relatively near its end. By knowing thedistance from the ultrasonic transducer(s) to the end of the tubularmember, once the tubular's outer surface has been examined, signalsother than those related to examination of the inner surface anddetermining the distance to the tubular end can be ignored.

In certain aspects a system according to the present invention employs atransducer mount or “shoe” that has a plurality (two, three, four, fiveor more) of ultrasonic transducers each of which can emit a beam that isreflected back to a receiving (“listening”) transducer. In one aspectthe reflected beams pass through a single beam passage area of the shoefor receipt by one of the transducers which is not in a beam-emittingmode (a “listening” mode).

In one embodiment a shoe according to the present invention has awaveguide support for transducers that is made of Lucite (trademark)plastic or of similar plastic (or of low loss ultrasonic material).Multiple—e.g., two, three, four or five—transducers are mountedrelatively close to each other. Each transducer is mounted at aprescribed angle so that, in certain aspects, all reflected beams passthrough the single beam passage area of the waveguide and are directedback to one of the transducers. In certain aspects such a system mayalso have one, two or more transducers located apart from the plasticwaveguide support for examining the wall thickness of the tubular beingstudied. Alternatively, the wall-thickness transducer(s) may also besupported by the plastic waveguide support. Optionally a wear member maybe mounted adjacent the plastic waveguide support and between it and atubular for contacting the outer surface of the tubular being examined.The wear member may be a plate with a curved surface corresponding inshape to the curved outer surface of the tubular; it may be a flexiblemember made of flexible rubber, plastic, or similar material; or it maybe an inflatable member such as a bladder or balloon whose contents(e.g. water that acts aa a waveguide) is adjusted to provide a shapethat corresponds to the shape of the tubular. Fluid inlet(s) andoutlet(s) in the shoe (e.g., but not limited to, in the plasticwaveguide support or a mount in which the plastic waveguide support isheld) provide fluid to the space between the wear member and the pipebeing inspected so that there is no air in this space to impedetransmission of the ultrasonic beams. Typical fluids for this includewater, silicone, oil, and/or glycol. With a plastic waveguide the angleof refraction of the material is typically about 35.8 degrees. Withsystems in which the ultrasonic beams are transmitted through water, theangle of refraction is typically about 18.8 degrees.

In certain systems and members according to the present invention a weldon, in or between tubular members is inspected. In one particularembodiment a girth weld (e.g. welding a tool joint to another piece ofpipe) is inspected for flaws. In one aspect such a system is automatedso that a welded tool joint is rotated adjacent a transducer mount withone, two, three, four, five or more. The transducer mount is movedaxially along the length of the joint as it rotates radially so that theentire weld is inspected. Any suitable apparatus for moving thetransducer mount adjacent the joint may be used. In one particularaspect the mount is moved continuously until it is adjacent a weldportion; then optionally the mount is moved so that in a positionimmediately past the weld and the mount is held stationary there whilethe joint continues to rotate radially adjacent the transducers—thusinsuring that the entire weld is inspected and the weld thickness pastthe weld is examined. Alternatively, the transducer mount is moved alongthe entire joint length in pre-set incremental steps and the final stepis of sufficient temporal duration that the joint continues to rotatethrough the final step duration so that the wall thickness of the entireweld is inspected. By purposefully moving an ultrasonic transducerapparatus very near or past a weld, the entire weld is subjected to afull ultrasonic beam width.

It is, therefore, an object of at least certain preferred embodiments ofthe present invention to provide:

New, useful, unique, efficient, nonobvious systems and methods fordetecting defects in tubular members such as pipe, casing, tubing, andother tubulars;

Such systems and methods which can effectively and efficiently inspectnearly all of the length of tubular members, etc. relatively near (e.g.within a few millimeters or within an eighth of an inch) the endsthereof for both outer and inner surface defects;

Such systems and methods which accurately distinguish and differentiatean I.D. flaw detection beam reflected from an inner surface defect neara pipe end from a pipe-end-reflected beam;

Such systems and methods which ignore information related to a signalfrom a pipe-end-reflected beam and/or which nullify or cancel such abeam so that it is not confused with or misinterpreted as anear-pipe-end inner-surface-defect-reflected beam;

New, useful, unique, efficient and nonobvious systems and methods withsingle beam passage areas for all of a plurality of ultrasonic beamsfrom a plurality of transducers used for tubular defect detection; and

New, useful, unique, efficient and nonobvious systems and methods forinspecting welds in, on, or between tubular members and for, in oneparticular aspect, inspecting entire girth welds of tool joints; and

Such systems and methods in which an ultrasonic transducer apparatus ispositioned very near or past a weld so that the weld is subjected to thefull beam width of an ultrasonic beam, which in one aspect is done bymoving the ultrasonic transducer apparatus in step-wise manner adjacentthe weld.

Certain embodiments of this invention are not limited to any particularindividual feature disclosed here, but include combinations of themdistinguished from the prior art in their structures and functions.Features of the invention have been broadly described so that thedetailed descriptions that follow may be better understood, and in orderthat the contributions of this invention to the arts may be betterappreciated. There are, of course, additional aspects of the inventiondescribed below and which may be included in the subject matter of theclaims to this invention. Those skilled in the art who have the benefitof this invention, its teachings, and suggestions will appreciate thatthe conceptions of this disclosure may be used as a creative basis fordesigning other structures, methods and systems for carrying out andpracticing the present invention. The claims of this invention are to beread to include any legally equivalent devices or methods which do notdepart from the spirit and scope of the present invention.

The present invention recognizes and addresses the previously-mentionedproblems and long-felt needs and provides a solution to those problemsand a satisfactory meeting of those needs in its various possibleembodiments and equivalents thereof. To one skilled in this art who hasthe benefits of this invention's realizations, teachings, disclosures,and suggestions, other purposes and advantages will be appreciated fromthe following description of preferred embodiments, given for thepurpose of disclosure, when taken in conjunction with the accompanyingdrawings. The detail in these descriptions is not intended to thwartthis patent's object to claim this invention no matter how others maylater disguise it by variations in form or additions of furtherimprovements.

DESCRIPTION OF THE DRAWINGS

A more particular description of embodiments of the invention brieflysummarized above may be had by references to the embodiments which areshown in the drawings which form a part of this specification. Thesedrawings illustrate certain preferred embodiments and are not to be usedto improperly limit the scope of the invention which may have otherequally effective or legally equivalent embodiments.

FIGS. 1A and 1B are perspective views of a transducer device accordingto the present invention. FIG. 1C is a bottom view of the device of FIG.1A.

FIG. 2A is top view of a base of the device of FIG. 1A FIG. 2B is abottom view of the base of FIG. 1A.

FIG. 3A is a top view of a wearplate of the device of FIG. 1A. FIG. 3Bis bottom view of the wearplate of FIG. 3A.

FIG. 4A is top perspective view of a waveguide support of the device ofFIG. 1A. FIG. 4B is a bottom perspective view of the waveguide supportof FIG. 4A.

FIG. 5A is top view of a transducer device according to the presentinvention. FIG. 5B is a cross-section view along line 5B—5B of FIG. 5A.FIG. 5C is a side view along of the device of FIG. 5A. FIG. 5D is abottom view of the device mount of FIG. 5A.

FIGS. 6A, 6C and 6E are schematic views of tubular inspection systemsaccording to the present invention. FIG. 6B is an end view of the systemof FIG. 6A. FIG. 6D is an end view of the system of FIG. 6C. FIG. 6F isan end view of the system of FIG. 6C.

FIG. 7 is a schematic view of signal processing according to the presentinvention.

FIGS. 8A-8D schematically illustrate an inspection method according tothe present invention.

FIGS. 9A and 9B are schematic views of systems according to the presentinvention.

FIGS. 10A, 10B, and 10C are schematic views of systems according to thepresent invention.

FIG. 11 is a schematic view of signal processing according to thepresent invention.

DESCRIPTION OF EMBODIMENTS PREFERRED AT THE TIME OF FILING FOR THISPATENT

FIGS. 1A-1C show a transducer device 10 according to the presentinvention for use with tubular inspection systems. The device 10 has abase 12; a waveguide support 30; ultrasonic transducers 50 a-50 d and 52on the waveguide support 30; and a wearplate 20 secured over one surfaceof the waveguide member 30.

FIGS. 2A-2E show details of the base 12 of the device 10 of FIG. 1. Thebase 12 has a body 14 with a recess 16 in which is positioned thewaveguide support 30. A bevelled opening 11 receives a correspondinglyshaped part of the waveguide support 30 as described below. A rollerassembly is secured to the base 12 and has rollers 15 secured to aspacer 19 by bolts 17. These rollers 15 contact the outer surface of atubular along which the device 10 is moved.

FIGS. 3A and 3B show the wearplate 20 which has a body 22; front face21; a beveled opening 27 corresponding in size and location to theopening 11 of the base 12 and through which projects part of thewaveguide support 30 as discussed below; and a rear face 23. The frontsurface 21 of the wearplate 20 is curved to correspond to the curvedsurface of a tubular being inspected with a system with a device 10,FIG. 1A. The wearplate 20, in certain embodiments, is made ofpolytetrafluoroethylene.

FIGS. 4A and 4B show the waveguide support 30 of the device 10 of FIG.1A. The transducers shown in FIGS. 1A and 1B have been deleted fromFIGS. 4A and 4B. The waveguide support 30 has a body 32 with fourspaced-apart pillars 31, each with a hole 33 in it for securing to thebase 12. The body 32 has four inclined surfaces 35 to which are securedtransducers 50 (see FIG. 1B). The transducers may be coupled with gel orother suitable material and/or held in place with screws or bolts usingholes 39. A top surface 34 of the body 32 may be vacant or, optionally,a transducer 52 (see FIG. 1B) may be secured there. A lower member 36projects down from the body 32. The lower member 36 may have a lowercurved portion 37 whose shape corresponds to that of the front surfaceof the wearplate and to the tubular's outer surface.

The distance “d” in FIG. 1A is the distance from the transducer 50 a tothe front end of the base 12. In certain aspects the base 12 is moved sothat the shoe progresses no further than the distance “d” to the end ofthe tubular being inspected. In other aspects the shoe is moved so thatthe opening 27 is beneath the end of the tubular. In other aspects theshoe is moved past the tubular end. In one particular embodiment thedistance “d” is about one inch. In certain aspects the opening 27 (andthe opening in any version of such a shoe) is about the same size as, isno less than in size, is between 5% to 30% larger in size than, or isabout 20% larger in size than the sensitive area of a crystal of anultrasonic transducer positioned near the opening.

In one embodiment the transducers (e.g., transducers as in FIG. 1A) in adevice according to the present invention are so positioned and thewaveguide support (e.g., the waveguide support 30) according to thepresent invention is so sized and configured with its surfaces anddimensions so that all beams—both initial transmitted sonic beams fromthe transducers and beams reflected from a tubular surface or from aflaw—pass through a single beam passage area (e.g. like the area betweenthe lower member 36 of the waveguide support 30 and through opening 27of the wearplate 20 and opening 11 of the base 12). In certain aspectsthe extent of the single beam passage area according to the presentinvention is slightly larger than the size (e.g., the area) of thesensitive area of the ultrasonic crystal of a transducer. In certainaspects the size of the single beam passage area is between 105% to 125%(or more) of the size of the transducer crystal's sensitive area and inone particular aspect the size of the area is 120% of the size thereof.

FIGS. 5A-5D show a transducer device 100 according to the presentinvention which has a body 102 to which are secured multiple transducers106 and an optional transducer 104. Each transducer 106 is mounted in acorresponding recess 107 in the body 102. The transducer 104 is mountedin a recess 108. The body 102 may be made of aluminum, of anothersuitable metal, of Lucite (trademark) plastic or of similar plastic ormaterial.

A bladder 120 is secured over a recess 114 in the body 102. Optionally aring (not shown) may be used to hold the bladder in place. Screwsthrough the ring pass into the holes 115 to hold the ring securely tothe body 102. Holes 112 provide for the flow of fluid to and from thebladder 120 directly from the holes 112 into the bladder so that theshape of the bladder 120 is adjustable to conform to the shape of a pipeP which is being inspected.

A “single area” 110 between the transducers 106 provides an area throughwhich both transmitted and reflected sonic beam(s) pass.

FIGS. 6A, 6C and 6E show schematically systems according to the presentinvention which use a transducer device according to the presentinvention to inspect tubulars.

FIGS. 6A and 6B show a system 160 according to the present inventionwhich has a pipe rotation system 162 for radially rotating a pipe 161and a sensing system 170 which includes a transducer system 171 with a“shoe” 172 with a plurality of transducers (e.g. but not limited to asin the systems of FIGS. 1A and 5A). Water is supplied to the transducersystem 171 by a water supply system 174. A shoe movement system 176 formoving the shoe 172 axially with respect to the pipe 161 includes amount 177 that is moved on a precision linear motion table 178 by amotor 179. A mounting bracket 164 supports a ball/screw apparatus 163(optionally with a tracking encoder apparatus 166) which is moved by themotor 179. A water tray 165 is positioned below the shoe 172. A PLCcontroller 173 controls the motor 179 and, if desired, the rotationsystem 162.

A system 180 according to the present invention shown in FIGS. 6C and 6Dis like the system 160 of FIG. 6A (like numerals indicate like parts);but the system 180 has an end sensor 182 which senses an end of the pipe161 and produces an electronic signal which is transmitted by the endsensor to the PLC controller 173. In response to this signal, the PLCcontroller 173 can decouple the transducers from the pipe 161 (move theshoe away from and out of contact with the pipe 161). The system 180also has a physical pipe stopper 184 which prevents further movement (tothe right in FIG. 6C) of the pipe. When the pipe stops the shoe 172 isin a known position with respect to the end of the pipe 161. The PLCcontroller and/or the transducer system are interconnected with acomputer or computers and/or monitors and/or display apparatus (e.g. asin FIG. 6E).

FIGS. 6E and 6F show a system 200 according to the present inventionwhich, in some respects, is similar to the systems of FIGS. 6A and 6C(like numerals indicate like parts). A pipe 161 to be rotated andinspected is radially rotated by a rotation system 162 while atransducer system 171 for inspecting the pipe 161 is moved adjacent thepipe 161. A powered conveyor roller 216 (or rollers) move the pipe 161axially (left and right in FIG. 6E) away from or toward a pipe stop 218.A water supply system 174 sprays water onto a shoe 172 of the transducersystem 171 to provide water coupling between the shoe and the pipe toassist the transmission of ultrasonic signals to and away from thetransducer system.

A water cleaning tray 222 receives excess water expelled by the shoe 172for disposal or for recycling in the system. Optionally, the tray 222 isremovable for cleaning dirt, debris, etc. accumulated therein. Acompliant mount/suspension system 202 provides apparatus for raising andlowering the shoe 172 and a flexible support for the shoe 172 toaccommodate irregularities and eccentricities in the pipe 161 as it isrotated adjacent the shoe 172. Any suitable known pipe rotation systemmay be used for the system 162. An optional pneumatic lift 204 raisesthe shoe 172 to contact the pipe 161 and lowers the shoe 172 tofacilitate pipe loading or unloading. The lift 204 is controlled by thePLC controller 173. Hose and cable management apparatus 206 holds andaccommodates various items—cables, wires, hoses, etc.—associated withthe provision of water, electrical power, and signals to the variousparts of the table 214 and parts of the system 200 (and such apparatus206 may be used in the systems of FIGS. 6A and 6C). All mechanicalfunctions of the system are controllable by the PLC controller.

A drive motor 208 mounted to the end of a ball/screw apparatus 212 movesthe shoe 172 axially along the pipe 161. The ball/screw apparatus ispart of a precision linear motion table 214 that accurately andprecisely, and with stability, moves the transducer system 171 withrespect to the pipe 161. The ball/screw apparatus 212 provides a lineardrive for the movement of the shoe 172 along the pipe 161; and theencoder 210, attached to the ball/screw apparatus, provides locationfeedback information to the PLC controller 173. The PLC controller 173and the ultrasonic transducers of the transducer system 171 provide datato a computer 220. The computer 220 is interconnected with either amonitor (or monitors) 221 and/or a strip chart recorder (or recorders)223 to display inspection results. In one aspect inspection results aredisplayed to system operators in real-time. Also the computer 220 may,in certain aspects, be programmed to provide an alarm signal to a PLCcontroller to activate an alarm when a flaw is detected. There may be analarm in or on the computer itself. Also, a known precision linearmotion table may be used for the table 214.

An end sensor 182 senses the location of the shoe 172 with respect tothe end of the pipe 161 and senses the location of the end of the pipe161 when the transducer system 171 nears the pipe end (the end to theright in FIG. 6E).

FIG. 7 illustrates schematically signal processing for an embodiment ofa system and method according to the present invention for inspectionsignal transmission and use according to the present invention. In oneaspect transducers 151-154 and 155—each with corresponding associatedinstrumentation 151 a-154 a correspond to the transducers 106 and 104,respectively, of the system 100 (FIG. 5A) or to the transducers 50 a-50d and 52, respectively of the system 10 (FIG. 1A). The transducers151-154 are for flaw detection and the transducer 155 is for measuringtubular member wall thickness. Ultrasonic electronic instrumentation isused which provides for the measurement of the amplitude of reflectedsonic beams and the measurement of the time of flight of sonic beams toindicate, locate, and measure I.D. flaws, O.D. flaws, wall thickness,and time of flight to the end of a tubular member. The instrumentationalso receives an interface signal that indicates the interface between atransducer and the tubular member as each firing sequence is initiated.

Each transducer is controlled by its associated instrumentation so thatit transmits its sonic beam at specified time intervals at a specifiedrepetition rate for a specified time duration, e.g., in some systems itmay range between 50 milliseconds and a second. By imposing theseelectronic time data correction windows or “gates” (“Interface Gate”) onthe transducers' operation, the instrumentation permits the collectionand processing of signal information only in the specified time windows.Thus if a flaw is indicated by a reflected signal, the location of theflaw is known. Each transducer can be used for both I.D. and O.D. flawdetection and for pipe end indication. A “Transverse Front” transducerfaces the front of the tubular member (e.g., transducer 50 a in FIG. 1A)and a “Transverse Back” transducer faces the back of the tubular member(e.g., transducer 50 b in FIG. 1A). A “Longitudinal Left” transducerfaces to the left (e.g., transducer 50 c in FIG. 1A) and “LongitudinalRight” transducer faces to the right (e.g., transducer 50 d in FIG. 1A).

A reflected beam is received back by a transducer following reflectionfrom an end of the tubular or from a flaw at a surface; and thetransducer then senses and receives an echo (reflected beam) which hasan amplitude. If the echo is relatively small (i.e. with little or noamplitude), no flaw is indicated; if the echo has an amplitude thatexceeds a pre-set value (programmed in the computer 156) then a flaw(“ID/OD Flaw”) is indicated. Optionally the computer 156 produces a flawalarm signal (“flaw alarm”; sound and/or visual). Flaw location and sizeare determined and are displayed by the computer 156. The transducerinstrumentation for the transducer 155 produces a time of flightmeasurement (time of flight of a compressional wave packet from theinterface, to the I.D. and back to the transducer) indicative of tubularwall thickness (“wall thickness”) which is transmitted to the computer156 (as digital information from the ultrasonic instrumentation) forwall thickness determination, alarm if necessary, and/or display.

When the transducer device nears the end of the pipe, a beam from thefront transducer (e.g. 50 a in FIG. 1A) reflects from the tubular end.Upon receipt of the beam reflected from the tubular end, the systemcalculates the distance from the front transducer to the end of thetubular (e.g. by using the time duration between an initial interfacepulse and the time of the pulse reflected from the tubular end). Thecalculated distance-to-the-end of the tubular indicates if thetransducer is at or near the end of the tubular member. When the fronttransducer has reached a position at which the system knows that theentire outer surface of the tubular has been inspected—a position nearthe tubular end at which part of the inner surface between the fronttransducer and the end of the tubular has not yet been inspected—thesystem continues with the inner surface inspection, ignoring any signalwhich may be received for time periods which would correspond to furtherouter surface inspection if the tubular end was not present; and whilethis inner surface inspection continues the system continuously detectsand calculates the distance to the tubular end so that inner surfaceinspection is stopped when the front transducer's I.D. beam widthreaches the tubular end. Due to the way in which the tubular member isrotated, the outer surface of the tubular member is completelyexamined—i.e., sonic beams are reflected from the entire outersurface—before the inner surface is completely examined. Therefore, thesystem, in certain aspects, ignores signals and their informationrelated to any reflected beam other than those related to inner surfaceexamination and end-reflected beams at a pre-set position of thetransducer device.

The device 156 may include: a screen (or screens) (or strip chartapparatus) that displays a graphical representation of a tubular beingexamined, in one aspect in cross-section, with initial interface, endreflections, surface reflections, and flaw reflections; a computer (orcomputers) for analyzing the various signals from the transducers and/orfrom the PLC controller, e.g. to determine transducer location, tubularend location, wall thickness, defect existence, defect location, defectorientation and defect signal amplitude; and, if determined, for sendingan alarm regarding insufficient wall thickness or defect indication; andfor generating a report to or display for an operator which may be aninteractive display to facilitate operational control of the system.Flaw location may be displayed in a two-dimensional display in which thehorizontal axis is the tubular length and the vertical axis is thetubular's circumference; or flaw-reflected signal amplitude may bedisplayed as a function of tubular length on a strip chart. Display ofthe results of the tubular examination, and flaw display, may be done(with any system disclosed herein) in “real time” so that an operatorsees (or is aware) of the detection of a defect as soon as the defect isdetected.

Optionally, a computer of the system has a “GO/NO GO” capability withwhich it compares flaw signal amplitude to a preset threshold—based onan acceptable or unacceptable size flaw. The system then indicateswhether the flaw renders the tubular acceptable or unacceptable.Similarly, the computer compares the amplitude of the wall thicknesssignal to a pre-set value to determine if the wall thickness isacceptable.

A programmable logic controller 157 (“PLC”) (e.g. like that of thesystems of FIGS. 6A, 6C, 6E) is interconnected electronically with: acomputer; a motor like the motor of the systems of FIGS. 6A and 6C formoving the transducer system longitudinally with respect to a tubular tobe inspected; the device 157 for providing information to the computer156 regarding the location, both longitudinally (“Head Linear Location”)and circumferentially (“Head Circumferential Location”), of thetransducer system; a tubular rotation system (“Pipe Rotation Control”)for controlling pipe rotation; an end sensor, like those of the systemsof FIGS. 6A, 6C, and 6E, for receiving from the end sensor a signalindicative of transducer system location (“Pipe End Photocell”) inreference to the tubular end; a mechanical and/or electronic and/orelectromagnetic device or apparatus (“Encoder”) that indicates locationof the transducer system with respect to the end of the tubular; systemfor indicating each rotation of the tubular, e.g. a magnetic tubularsensing system or a light sensing system with a photocell that indicateseach rotation of the tubular (e.g., in one aspect by sensing areflective area on the tubular each time it rotates past a photocell,e.g. a reflector or reflective tape or paint at a 12 o'clock position onthe tubular) (“12:00 Prox”). In one particular aspect the PLC controller157 activates the motor that moves the transducer system (“head”) insteps so that the end part of the tubular is examined (with thetransducers stationary between steps and the tubular still rotatingthrough 360 degrees for each step as described above). In other aspectsthe motor itself includes apparatus that activates the motor in steps(in one aspect commonly called a “Stepping Motor”), so that a full andcomplete inspection of a tubular is obtained, e.g. a shoe, for eachrotation of the pipe, is indexed in steps or advanced in increments thatare a fraction of the transducer beam width (e.g., but not limited to,{fraction (1/32)}, {fraction (1/16)}, ⅛, ¼, ½).

FIGS. 8A-8D illustrate the operation of an automated tubular inspectionsystem according to the present invention (like any of the systemsdescribed herein) and show the end and near-end inspection of a tubular(“pipe”) with an ultrasonic transducer system.

As shown in FIG. 8A a front transducer (“UT TRANSDUCER”) adjacent anouter surface (“OD”) of a tubular member (“PIPE”) at a specific time(horizontal axes are time axes) has fired an ultrasonic pulse (“SOUNDBEAM”) into the pipe a shear wave packet that has twice hit the pipe'sinner surface (“ID”), once hit the pipe's outer surface, and has hit theend of the pipe at the outer surface (“END OF PIPE”). At this transducerlocation, the entire outer surface of the pipe has been examined (i.e.,probed with a sonic beam); and a portion “a” of the pipe's inner surfacehas not yet been inspected. The sonic beam from the transducer followsthe indicated path in both transmission and reflection. The transducersends a sonic beam (a shear wave packet) directly across the pipe(upwards in FIG. 8A) which reflects back to the transducer from the pipeID, producing the “INTERFACE SIGNAL” which indicates the transducer'slocation at the time of the sonic beam shown in FIG. 8A on the lowermost“TIME” axis. The reflection back from the end of the pipe produces “PIPEEND SIGNAL” shown on the lowermost time axis. The time differentialbetween the interface signal and the pipe end signal provides the basisfor calculating the distance from the transducer to the end of the pipe.The computer using the speed of the sonic beam and the elapsed timebetween signals determines the distance to the pipe end. The transducerinstrumentation is programmed with various time windows (“GATES”) inwhich the transducer is activated to receive echoes from specificplaces; the “INTERFACE GATE” is a pre-set time window during which thetransducer is operational for receiving the interface signal; the “IDGATE” is a pre-set time window pre-set for a specified time after theinterface signal during which the transducer is operational forreceiving an echo from the pipe ID of the sonic beam's first hit on thepipe ID following transmission of the sonic beam from the transducer;the “OD GATE” is a pre-set time window pre-set for a specified timeafter the interface signal during which the transducer is operationalfor receiving an echo from the sonic beam's first hit on the pipe OD;and the “PIPE END GATE” is a pre-set time window during which thetransducer is operational for receiving an echo from the pie end.

As shown in FIG. 8A, the sonic beam has encountered no tubular defect ateither pipe surface and no defect signal is indicated on lowermost timeaxis. Any defect within the ID GATE or OD GATE would have resulted inthe production of a signal with an amplitude above that of the lowermosttime axis.

The temporal duration of the three gates shown in FIG. 8A is based onthe velocity of sound through the material of the particular tubularmember and its wall thickness. Once they are determined, these gates areset (by an operator) in the transducer instrumentation.

As shown in FIG. 8B the transducer has moved closer to the pipe end;except for the length “b”, the pipe's inner surface has been inspected;except for the length “c” (which is less than the length “b”) the pipe'souter surface has been inspected; and no defect has been detected. ThePIPE END SIGNAL indicates that the transducer is a distance “d” from thepipe end.

As shown in FIG. 8C, the entire pipe outer surface has been examined; alength “e” of the pipe's inner surface has not yet been examined; andthe transducer is a distance “f” from the pipe end. Signals from theO.D. gate are not originated by an O.D. flaw and are, therefore ignored;i.e., the system is now programmed to look for the pipe end in the pipeend gate and to ignore as an indication of an O.D. flaw and signals fromthe O.D. gate since the O.D. examination has been completed—there is nomore pipe outer surface to be examined, no more pipe outer surface past(to the right in FIG. 8C) the pipe end.

As shown in FIG. 8D, once the entire outer surface has been inspected(shown in FIG. 8C) the transducer continues to move toward the pipe endtransmitting the sonic beam to inspect the remaining portion (length“e”) of the inner surface while continuously receiving the end signalthat indicates that the transducer is getting closer and closer to thepipe end. Thus, the inspection of the entire inner surface is completed;at which point the pipe end signal indicates that the transducer is atthe end of the pipe and the system moves the transducer system away fromthe pipe (decouples it).

In order to accurately ascertain the distance to the end of the pipe, tofinish and complete the pipe I.D. inspection, and to insure that thepipe end is sensed when the transducer moves to a point adjacent thepipe end, the PIPE END GATE is moved so that it begins immediately afterthe completion of the ID GATE. The movement of the shoe with thetransducers is halted when the inspection has been completed.

The “UNINSPECTED LENGTH” in FIG. 8D indicates the length of the I.D.that has not yet been inspected due to the limitations of distinguishinga relatively small flaw signal from a relatively large end signal.

For illustrative purposes a flaw signal FS is shown on FIG. 8D whoseamplitude (height in FIG. 8D above the lower most time axis) is lessthan the amplitude of the INTERFACE SIGNAL and less than the amplitudeof the PIPE END SIGNAL. The amplitude of the flaw signal FS can providea defect indication which indicates that a defect of such extent ispresent that the pipe may be rejectable; i.e. the amplitude exceeds athreshold amplitude (an amplitude initially calibrated for flaws from afixed known reference flaw). In one aspect this threshold amplitude isthe height of the I.D. gate. The system provides an alarm as discussedabove when there is a defect indication and/or optionally provides a “NOGO” indication for the rejection of the tubular being examined.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a method for ultrasonically inspecting atubular member, the tubular member having an inner surface, an outersurface, and two spaced-apart ends including a first end of the tubularmember, the method including transmitting sonic beams to the tubularmember with one or more transducers such that sonic beams are reflectedfrom: the inner surface of the tubular member, the outer surface of thetubular member, and from the first end of the tubular member; completingand/or ceasing inspection of the outer surface of the tubular member forouter surface defects while continuing to inspect the inner surface ofthe tubular member for inner surface defects; while continuing toinspect the inner surface of the tubular member for inner surfacedefects after ceasing outer surface inspection, sensing a distance fromthe transducer(s) to the first end of the tubular member, and, thetransducer(s) continuing to transmit sonic beams for the inspection ofthe inner surface of the tubular member until the transducer(s) are nearthe first end of the tubular member.

Such a method may also include one, some (in any possible combination)or all of the following: wherein the tubular member has an inner surfacedefect near the first end of the tubular member and the method includingtransmitting a sonic beam from the transducer(s) such that the sonicbeam is reflected from the inner surface defect, receiving the reflectedbeam from the inner surface defect of the tubular member, producing adefect signal related to the sonic beam reflected from the inner surfacedefect, the defect signal for conveying information about the innersurface defect, and transmitting the defect signal to signal analysisapparatus to analyze and indicate the inner surface defect; producing anend signal related to a beam reflected from the first end of thetubular, the end signal having information, e.g. in digital form, aboutthe first end of the tubular member, calculating an end distance fromthe transducer(s) to the first end of the tubular member using theinformation of the end signal, and until the end distance is less than afirst pre-set value continuing to inspect the surfaces of the tubularmember; until the end distance is less than a second pre-set value,continuing to inspect the outer surface of the tubular member; when theend distance is less than the second pre-set value, continuing toinspect the inner surface of the tubular member; when the end distanceis less than the first pre-set value, ceasing inspection of the innersurface of the tubular member; wherein the first pre-set value isone-eighth of an inch; wherein the first pre-set value is two or threemillimeters; wherein the inner surface defect is within two or threemillimeters of the first end of the tubular; wherein the inner surfacedefect is within one-eighth of an inch of the first end of the tubular;wherein substantially all of the surface of the tubular member isaccurately inspected for inner surface defects; wherein each transducerhas associated instrumentation for controlling each transducer; whereina programmable logic controller controls movement means that moves thetubular member during inspection of the tubular member and that movesthe transducer(s) with respect to the tubular member; wherein a computeror computers analyze signal information and associated display apparatusdisplays inspection results; providing relative helical motion betweenthe tubular member and the transducer(s) to trace a helical path aroundthe surfaces of the tubular member with the sonic beams; transmittingsonic beams longitudinally and transversely through the member withtransducers; wherein the sonic beams are transmitted longitudinally,transversely, and obliquely into the tubular member; wherein thetransducer(s) are mounted on a waveguide support having a single beampassage area and the reflected beams bass through the single beampassage area; tracking a position of the transducer(s) and producing alocation signal indicative of said position(s); stopping relative motionbetween the tubular member and the transducer(s) when said locationsignal indicates that the transducer(s) are within a pre-set distance toan end of the tubular member; wherein movement of the tubular member isstopped by stopper apparatus; wherein an end of the tubular member issensed with end sensor apparatus and the end sensor apparatus sends anend signal to a control system that controls movement of thetransducer(s), receipt of the end signal by the control system, andstopping movement of the transducer(s) by the control system in responseto the end signal; moving the transducer(s) in indexed step increments;wherein each indexed step increment of the indexed step increments is afraction of a beam width of a sonic beam from the transducer(s); and/orwherein the fraction is from the group consisting of {fraction (1/32)},{fraction (1/16)}, ⅛, ¼, and ½.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a method for ultrasonically inspecting atubular member, the method including transmitting sonic beams throughthe tubular member with at least one transducer so that sonic beams arereflected from an inner surface of the tubular member, from an outersurface of the tubular member, and from defects of the tubular member,if any; and receiving with the at least one transducer reflected beamsfrom the surface defects of the tubular member, if any, from the innersurface and from the outer surface of the tubular member; sensing an enddistance from the at least one transducer to an end of the tubularmember, and ceasing inspection (either O.D., I.D., or both) of thetubular member when the end distance is less than a pre-set value.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, an ultrasonic inspection device useful forinspecting a tubular member having one or more transducers fortransmitting sonic beams and for receiving reflected beams thereof frominner and outer surfaces of the tubular member, from ends of the tubularmember including a first end spaced apart from a second end, and fromdefects of the tubular member, the reflected beams including beamsreflected from an outer surface of the tubular member, from an innersurface of the tubular member, from the first end of the tubular member,and from an inner surface defect of the tubular member, and means fordifferentiating the reflected beams, means for producing signalscorresponding to information about the reflected beams, including adefect signal having information about the inner surface defect, and anend signal having information about the end of the tubular member, andmeans for continuing inspection of the inner surface of the tubularmember for inner surface defects (in one aspect after ceasing to inspectthe O.D.) until the end distance is less than a pre-set value. Such amethod may also include one, some (in any possible combination) or allof the following: means for ceasing inspection of the outer surface ofthe tubular member when all but about one-eighth of an inch of thetubular member's length has been inspected; means for providing relativehelical motion between the tubular member and the transducer(s) to tracea helical path with sonic beams around the tubular member; means forindicating position of the transducer(s) with respect to an end of thetubular member; the means for indicating the position of thetransducer(s) including encoder apparatus; the means for indicating theposition of the transducer(s) including end sensor apparatus; means forenergizing and de-energizing the transducer(s) to sequentially transmitand receive sonic beams; an array of opposing transducers fortransmitting sonic beams, and transducer positioning means to which thetransducer(s) are connected for positioning the transducer(s) totransmit the sonic beams longitudinally, transversely, and obliquelythrough the tubular member such that beams are reflected from parts ofthe tubular member; a wall thickness transducer for measuring time ofsonic beam flight to determine tubular member wall thickness; waveguidesupport apparatus supporting the transducer(s) and having a single beampassage area through which all transmitted and reflected beams pass;and/or means for moving the transducer(s) in indexed steps with respectto the tubular member.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a waveguide support for an ultrasonicinspection device useful for inspecting tubular members, the waveguidesupport for supporting one or a plurality of ultrasonic transducers, thewaveguide support including a body of waveguide material, the bodyhaving a single beam passage area through which sonic beams from all ofthe ultrasonic transducer(s) are passable and back through which allsonic beams reflected from the tubular member are passable back to thetransducers. Such a method may also include one, some (in any possiblecombination) or all of the following: a plurality of transducers on thebody for transmitting sonic beams and for receiving reflected beamsthereof from the tubular member; at least one transducer having asensitive crystal area and the single beam passage area slightly largerthan the sensitive crystal area; and/or wherein the at least onetransducer is a plurality of transducers each with a sensitive crystalarea of substantially the same area.

The present invention, therefore, provides in certain, but notnecessarily all embodiments, a method for ultrasonically inspecting aweld on a tubular member, the method including transmitting sonic beamsfrom one or more ultrasonic transducers to inspect the weld, receivingreflected beams from the weld, and moving the ultrasonic transducersadjacent the weld in step-wise manner; such a method wherein eachtransducer has associated instrumentation for controlling eachtransducer, and wherein a programmable logic controller controlsmovement means that rotates the tubular member with respect to theultrasonic transducer(s) and wherein movement means moves thetransducer(s) with respect to the tubular member; and/or means forproviding relative helical motion between the tubular member and thetransducer(s) to trace a helical path of sonic beams from the ultrasonictransducer(s) around the tubular member, and means for indicatingposition of the transducer(s) with respect to an end of the tubularmember.

FIG. 9A shows a system 250 according to the present invention which islike other systems according to the present invention described herein,e.g. like the systems of FIGS. 6A, 6E and 8A, and parts like those ofthe system of FIG. 6A have like numerals. However, the system 250 hasone or two proximity switches 251, 252 (or photocell sensor apparatuses)which are activated by passage of a UT transducer system 271 [and itsaccompanying instrumentation 253 (like instrumentation 151 a-155 a, FIG.7] for providing ID and OD flaw inspection (like, e.g., the transducersystem 171, FIG. 6A) near the proximity switches. Alternatively, rod,beam or other suitable member 255 (see FIGS. 10A, 10B) connected to theUT transducer system 271 is located so that the rod 255 moves adjacentthe proximity switch(es), thereby activating it or them so that it orthey send a signal to the PLC controller 173 to stop inspection of theOD or ID, respectively, of a pipe 161 being inspected. It is to beunderstood that other components of a system according to the presentinvention like that described above (e.g. FIGS. 6A-7) are present forthe system 250 (e.g., but not limited to pipe rotation apparatus, likethe system 162, FIG. 6A; sensing system, like the system 170, FIG. 6A;water supply system, like the system 174, FIG. 6A; transducerinstrumentation apparatus; shoe and shoe movement system, like the shoe172 and system 176, FIG. 6A; mount and precision linear motion table,like the mount 177 and table 178, FIG. 6A; etc); but the computer 156 isdeleted and no sensing of the distance to the end of the pipe is done(since the “ID PROX” proximity switch signals when the UT transducer isat a point at which ID inspection can cease. Alternatively a drivemotor/drive shaft apparatus may be used to move the UT transducersystem.

As shown in FIG. 9B, the location of the UT transducer 271 is controlledby the PLC controller 173. Any desired number of UT transducers may beused (e.g., but not limited to, ten tarnsducers on a waveguide or shoe).Upon receipt of a signal from the OD proximity switch 251 that it hassensed the UT transducer 271 (or a rod 255 extending therefrom asillustrated in FIG. 10A), the PLC controller ignores OD signals from theUT Instrumentation 253 and thus inspection of the OD of the pipe 161ceases (e.g. within a preset distance of the pipe end, e.g. withinone-eighth or one sixteenth inch of an end of the pipe—and the system,as any herein, can inspect up to such a distance with respect to bothends of a pipe). The OD proximity switch 251 is located at a positioncorresponding to a location past which the UT transducer 271 wouldinspect an end portion of the pipe 161, e.g., as shown, the last ⅛ inchof the pipe, although in other embodiments according to the presentinvention the OD proximity switch may be located any desired distancefrom the pipe end, including, but not limited to, ¼ inch or {fraction(1/16)} inch. This location can take into account the “footprint” orwidth of the ultrasonic beam being used. An OD flaw signal from the UTinstrumentation will be ignored by the PLC controller 173 once the ODproximity switch 251 has sent its signal (or in other aspects in whichan ID proximity switch is first encountered, an ID flaw signal will beignored by the PLC controller). A pipe stopper 284 physically stopd thepipe.

After the OD inspection ceases, ID inspection continues until, as shownin FIG. 10B, the rod 257 moves adjacent the ID proximity switch 252 atwhich point it sends a signal to the PLC controller 173. The PLCcontroller 173 then ignores further ID signals from the UTInstrumentation upon movement of the UT transducer 271 back to aninitial position adjacent a “START” proximity switch 258. The PLC issignalled so that it knows that the UT transducer 271 is again inposition to start an inspection.

Optionally, an alarm (audio and/or visual) may be interconnected withthe PLC controller for activation upon receipt of a flaw signal(provided that the proximity switch has not been encountered). As shownin FIG. 9B an audio alarm 259 provides a sound alarm upon receipt of aflaw signal. “START PROX” in FIGS. 9A and 9B indicate a proximity switch(or photocell) at the beginning of the travel of the UT transducer 271.If an OD or an ID flaw is detected by the system 250 between thestarting proximity sensor (“START PROX”) and the OD proximity switch 251and ID or OD alarm signal is sent to the PLC controller 173 and acorresponding alarm signal is sent from the PLC controller to the alarm259 and an audio alarm is sounded (or alternatively a flashing light isused). If an ID flaw in the pipe 161 is sensed between the OD proximitysensor and the ID proximity sensor, an ID alarm signal is sent by the UTinstrumentation 253 to the PLC controller 173 and an ID flaw alarm isgenerated. Any system according to the present invention may employ anID proximity switch, an OD proximity switch, or both, with or withoutcorresponding rods 255, 257. Any alarm herein may also indicate anddifferentiate between an ID flaw and an OD flaw.

As shown in FIG. 10A, the OD proximity switch 251 can be located so thatan ultrasonic pulse 277 from the UT transducer 271 is reflected from theID wall of the pipe 161 and then hits an OD notch 256 which is a desireddistance from the end of the pipe (e.g. ⅛″ as shown, or, preferably,between ¼″ and {fraction (1/16)}″). The OD notch 256 is made in the pipeprior to inspection. Similarly, as shown in FIG. 10B, the ID proximityswitch 252 can be located with respect to an ID notch 253 so that anultrasonic pulse 278 from the UT transducer 271 hits an ID notch 253(made in the pipe prior to inspection and located a desired knowndistance from the pipe end—as shown, ⅛″). Thus the ID and OD notchesare, in effect, detectable artificial flaws positioned in a knownlocation.

As shown in FIGS. 10A and 10B, for OD notch detection the ultrasonicpulse is reflected once (FIG. 10A) from the pipe ID wall before itcontacts the OD notch (the pulse has two “legs”) and the ultrasonicpulse is not reflected (FIG. 10B) from the pipe wall before it hits theID notch (the pulse has one “leg”); but, it is within the scope of thepresent invention (for any system and method disclosed herein) to use amulti-legged pulse (e.g. three, five, or more legs) for contacting theID notch and a multi-legged pulse (e.g., two, four, six or more legs)for contacting the OD notch. The location of the ID notch and/or ODnotch is adjusted depending on the number of reflections (legs) used andthus the ID proximity switch and/or OD proximity switch will have acorresponding location with respect to the pipe end (a locationcorresponding to the location of the UT transducer when it emits theknown multi-leg pulse). It should also be noted that, according to thepresent invention, it is, therefore, possible to have the UT transducerfirst encounter an ID proximity switch prior to encountering an ODproximity switch. For example, as shown in FIG. 10C, the UT transducerencounters an ID proximity switch 252 a prior to encountering an ODproximity switch 251 a—and the ultrasonic pulse from the UT transducer271 that contacts the ID notch 253 a and which is reflected once fromthe pipe ID wall 161 a and once from the pipe OD wall 161 b (i.e., thepulse has three “llegs”). As shown in FIG. 10C the ultrasonic pulse fromthe UT transducer when it is adjacent the OD proximity switch 251 a willhave two legs, but, as described above, a multi-legged pulse of four ormore legs may be used for OD notch detection with the OD proximityswitch located appropriately. It is within the scope of the presentinvention to use such multi-legged pulses for any system according tothe present invention, including, but not limited to, those referred towith respect to FIGS. 6A, 6E, 7, 8A, and 9A.

FIG. 11 shows schematically an instrumentation/control diagram for asystem like the system 250 according to the present invention like thatof FIG. 9A which has no computer 156 (like that in FIG. 7) and in whichno signal related to distance-to-end-of-pipe is sent by a UT transducerto a PLC controller. The system shown in FIG. 11 has four transducers271 (the top four) and a wall thickness transducer 275 each withcorresponding instrumentation 253, 276, respectively. It is within thescope of this invention to use any suitable known logic control signalprocessing device for the PLC controller.

The present invention provides, therefore, in some but not necesssarilyall embodiments, a method for ultrasonically inspecting a tubularmember, the tubular member having a first surface, a second surface, thefirst surface spaced apart from the second surface by a thickness of thetubular member, and two spaced-apart ends including a first end of thetubular member, the method including transmitting sonic beams to thetubular member with transducer apparatus such that sonic beams arereflected from the first surface of the tubular member and from thesecond surface of the tubular member, the transducer apparatuscontrolled by control apparatus, while continuing to inspect the firstsurface of the tubular member for first surface defects, moving thetransducer apparatus adjacent sensing apparatus which signals thecontrol apparatus to cease processing of transducer apparatus signalsrelated to inspection of the second surface, and, the transducerapparatus continuing to transmit sonic beams for the inspection of thefirst surface of the tubular member, and completing inspection ofsubstantially all of the second surface of the tubular member for secondsurface defects while continuing to inspect the first surface of thetubular member for first surface defects. Such a method may include oneor some, in any possible combination, of the following: wherein thefirst surface is a surface of an inner wall of the tubular member andthe second surface is a surface of an outer wall of the tubular member,or vice-versa; wherein the control apparatus comprises a logic controlsignal processing device; wherein the sensing apparatus is a secondproximity switch activatable by the presence of the transducer apparatusadjacent said proximity switch; wherein the sensing apparatus includes afirst proximity switch for signalling the control apparatus to ceaseprocessing of transducer apparatus signals related to inspection of thefirst surface, the method further including completing inspection ofsubstantially all of the first surface of the tubular member for firstsurface defects; wherein completion of inspection of substantially allof the tubular member for both first surface defects and second surfacedefects includes inspecting the tubular member's length up to a distancebetween one four and one sixteenth inches from the first end, with thefirst and second proximity switches correspondingly positioned for saidinspection completion; wherein the tubular member has a surface and themethod further including transmitting a sonic beam from the transducerapparatus such that the sonic beam is reflected from the inner surfacedefect, receiving the reflected beam from the surface defect, producinga defect signal related to the sonic beam reflected from the surfacedefect, the defect signal for conveying information about the surfacedefect, and transmitting the defect signal to signal analysis apparatusto analyze and indicate the surface defect; wherein the surface defectis a first surface defect; wherein the surface defect is a secondsurface defect; wherein substantially all of the entire surface of thetubular member is accurately inspected for surface defects; wherein thetransducer apparatus has associated instrumentation for the transducerapparatus wherein a programmable logic controller controls movementapparatus that moves the tubular member during inspection of the tubularmember and that moves the transducer apparatus with respect to thetubular member; wherein associated display apparatus displays inspectionresults; providing relative helical motion between the tubular memberand the transducer apparatus to trace a helical path around the surfacesof the tubular member with the sonic beams; transmitting sonic beamslongitudinally and transversely through the member with the transducerapparatus; wherein the sonic beams are transmitted longitudinally,transversely, and obliquely into the tubular member; wherein thetransducer apparatus is mounted on a waveguide support having a singlebeam passage area and the reflected beams bass through the single beampassage area; tracking a position of the transducers and/or producing alocation signal indicative of said position; stopping relative motion ofthe tubular member with a pipe stopper; wherein the transducer apparatusincludes multiple ultrasonic transducers; moving the transducerapparatus in indexed step increments; and/or wherein each indexed stepincrement of the indexed step increments is a fraction of a beam widthof a sonic beam from the transducers.

The present invention provides, therefore, in at least certainembodiments, an ultrasonic inspection device useful for inspecting atubular member having transducer apparatus for transmitting sonic beamsand for receiving reflected beams thereof from inner and outer surfacesof the tubular member, and from defects of the tubular member, thereflected beams including beams reflected from an outer surface of thetubular member and from an inner surface of the tubular member, and froma defect of the tubular member, and apparatus for differentiating thereflected beams, apparatus for producing signals corresponding toinformation about the reflected beams, including a defect signal havinginformation about the defect, and an end signal from proximity switchapparatus positioned with respect to an end of the tubular member, andapparatus for continuing inspection of one surface of the tubular memberfollowing cessation of inspection of the other surface of the tubularmember; and such an ultrasonic inspection device with apparatus forceasing inspection of the tubular member when all but about one-eighthof an inch at one end or at both ends of the tubular member's length hasbeen inspected.

In conclusion, therefore, it is seen that the present invention and theembodiments disclosed herein and those covered by the appended claimsare well adapted to carry out the objectives and obtain the ends setforth. Certain changes can be made in the subject matter withoutdeparting from the spirit and the scope of this invention. It isrealized that changes are possible within the scope of this inventionand it is further intended that each element or step recited in any ofthe following claims is to be understood as referring to all equivalentelements or steps. The following claims are intended to cover theinvention as broadly as legally possible in whatever form it may beutilized. The invention claimed herein is new and novel in accordancewith 35 U.S.C. §102 and satisfies the conditions for patentability in§102. The invention claimed herein is not obvious in accordance with 35U.S.C. §103 and satisfies the conditions for patentability in §103. Thisspecification and the claims that follow are in accordance with all ofthe requirements of 35 U.S.C. §112. The inventors may rely on theDoctrine of Equivalents to determine and assess the scope of theirinvention and of the claims that follow as they may pertain to apparatusnot materially departing from, but outside of, the literal scope of theinvention as set forth in the following claims.

What is claimed is:
 1. A method for ultrasonically inspecting a tubularmember, the tubular member having a first surface and a second surface,the first surface spaced apart from the second surface by a thickness ofthe tubular member, and two spaced-apart ends including a first end anda second end of the tubular member, the method comprising transmittingsonic beams to the tubular member with transducer apparatus such thatsonic beams are reflected from the first surface of the tubular memberand from the second surface of the tubular member, the transducerapparatus controlled by control apparatus, while continuing to inspectthe first surface of the tubular member for first surface defects,moving the transducer apparatus adjacent sensing apparatus which signalsthe control apparatus to cease processing of transducer apparatussignals related to inspection of the second surface, and, the transducerapparatus continuing to transmit sonic beams for the inspection of thefirst surface of the tubular member, and completing inspection ofsubstantially all of the second surface of the tubular member for secondsurface defects while continuing to inspect the first surface of thetubular member for first surface defects.
 2. The method of claim 1wherein the first surface is a surface of an inner wall of the tubularmember and the second surface is a surface of an outer wall of thetubular member.
 3. The method of claim 1 wherein the first surface is asurface of an outer wall of the tubular member and the second surface isa surface of an inner wall of the tubular member.
 4. The method of claim1 wherein the control apparatus comprises a logic control signalprocessing device.
 5. The method of claim 1 wherein the sensingapparatus is a second proximity switch activatable by the presence ofthe transducer apparatus adjacent said proximity switch.
 6. The methodof claim 5 wherein the sensing apparatus includes a first proximityswitch for signalling the control apparatus to cease processing oftransducer apparatus signals related to inspection of the first surface,the method further comprising completing inspection of substantially allof the first surface of the tubular member for first surface defects. 7.The method of claim 6 wherein completion of inspection of substantiallyall of the tubular member for both first surface defects and secondsurface defects includes inspecting the tubular member's length up to adistance between one four and one sixteenth inches from each end of thetubular member, with the first and second proximity switchescorrespondingly positioned for said inspection completion.
 8. The methodof claim 5 wherein either the first surface or the second surface of thetubular member is an inner surface of the tubular member and the methodfurther comprising transmitting a sonic beam from the transducerapparatus such that the sonic beam is reflected from an inner surfacedefect receiving the reflected beam from the inner surface defect,producing a defect signal related to the sonic beam reflected from theinner surface defect, the defect signal for conveying information aboutthe inner surface defect, and transmitting the defect signal to signalanalysis apparatus to analyze and indicate the inner surface defect. 9.The method of claim 8 wherein the surface defect is a first surfacedefect.
 10. The method of claim 8 wherein the inner surface defect is asecond surface defect.
 11. The method of claim 1 wherein means areprovided for producing an alarm when a surface defect is detected, themethod further comprising providing an alarm when a surface defect isdetected.
 12. The method of claim 1 wherein the transducer apparatus hasassociated instrumentation for the transducer apparatus.
 13. The methodof claim 1 wherein a programmable logic controller controls movementmeans that moves the tubular member during inspection of the tubularmember and that moves the transducer apparatus with respect to thetubular member.
 14. The method of claim 13 wherein associated displayapparatus displays inspection results.
 15. The method of claim 1 furthercomprising providing relative helical motion between the tubular memberand the transducer apparatus to trace a helical path around the surfacesof the tubular member with the sonic beams.
 16. The method of claim 1further comprising transmitting sonic beams longitudinally andtransversely through the member with the transducer apparatus.
 17. Themethod of claim 1 wherein the sonic beams are transmittedlongitudinally, transversely, and obliquely into the tubular member. 18.The method device of claim 1 wherein the transducer apparatus is mountedon a waveguide support having a single beam passage area and thereflected beams bass through the single beam passage area.
 19. Themethod of claim 1 further comprising the steps of tracking a position ofthe transducer apparatus and producing a location signal indicative ofsaid position.
 20. The method of claim 1 further comprising the steps ofproviding relative motion of the tubular member and stopping relativemotion of the tubular member with a pipe stopper.
 21. The method ofclaim 1 wherein the transducer apparatus includes multiple ultrasonictransducers.
 22. The method of claim 1 further comprising moving thetransducer apparatus in indexed step increments.
 23. The method of claim22 wherein each indexed step increment of the Indexed step increments isa fraction of a beam width of a sonic beam from the transducerapparatus.
 24. An ultrasonic inspection device useful for inspecting atubular member comprising transducer apparatus for transmitting sonicbeams and for receiving reflected beams thereof from inner and outersurfaces of the tubular member, and from defects of the tubular member,the reflected beams including beams reflected from an outer surface ofthe tubular member and from an inner surface of the tubular member, andfrom a defect of the tubular member, and means for differentiating thereflected beams, means for producing signals corresponding toinformation about the reflected beams, including a defect signal havinginformation about the defect, and an end signal from proximity switchapparatus positioned with respect to an end of the tubular member, andmeans for continuing inspection of one surface of the tubular memberfollowing cessation of inspection of the other surface of the tubularmember.
 25. The ultrasonic inspection device of claim 24 furthercomprising means for ceasing inspection of the tubular member when allbut about one-eighth of an inch at one end of the tubular member'slength has been inspected.